Methods for forming light active devices

ABSTRACT

A method is provided for forming a light active device. A fluid carrier has light active particulate dispersed within it. A first electrode layer is provided and a layer of the fluid carrier dispersed with the light active particulate is laminated or coated on the first electrode layer. A second electrode layer is provided on top of the laminated layer of the fluid carrier dispersed with the light active particulate. The light active particulate may comprise field reactive light active particulate randomly dispersed within the fluid carrier. An aligning field is applied between the first electrode and the second electrode to form a desired alignment of the field reactive light active particulate within the fluid carrier between the first electrode and the second electrode. The carrier may comprise a hardenable material. The carrier can be hardened to form a hardened carrier for maintaining the desired alignment of the light active particulate within the hardened carrier. The light active particulate can be effective for receiving through the carrier electrical charges from the first electrode layer and the second electrode layer and generating photon emissions in response to receiving said electrical charges. The light active particulate can be effective for receiving a photon and separating electrical charges in response to the received photon, the separated electrical charges being transfer through the carrier to the first electrode layer and the second electrode.

CROSS REFERENCE TO RELATED APPLICATIONS

This is a Divisional Patent Application of U.S. Utility patentapplication Ser. No. 10/321,161, filed Dec. 17, 2002, which is the USUtility Patent Application of a Provisional Patent Application Ser. No.60/427,333.

BACKGROUND OF THE INVENTION

The present invention pertains to organic light active devices. Moreparticularly, the present invention pertains to devices and methods forfabricating organic light active devices that can be used forapplications such as general lighting, display backlighting, videodisplays, maps, digital newspapers, stereoscopic vision aides, advancedvehicle windshields, solar cells, cameras and photodetectors.

Organic light active material (“OLAM™”) makes use of the relativelyrecent discovery that polymers can be made to be conductors. Organiclight emitting diodes (“OLED”) convert electrical energy into light,behaving as a forward biased pn junction. OLAMs can be light emitters orlight detectors, depending on the material composition and the devicestructure. For the purpose of this disclosure, the term OLAM and OLEDcan be interchanged. In its basic form, an OLED is comprised of a layerof hole transport material upon which is formed a layer of electrontransport material. The interface between these layers forms aheterojunction. These layers are disposed between two electrodes, withthe hole transport layer being adjacent to an anode electrode and theelectron transport layer being adjacent to a cathode electrode. Uponapplication of a voltage to the electrodes, electrons and holes areinjected from the cathode electrode and the anode electrode. Theelectron and hole carriers recombine at the heterojunction formingexcitons and emitting light.

The basic structure of an OLED display is similar to a conventional LCD,where the reactive material (in the LCD case, a liquid crystal, in theOLED case, a conjugate polymer) is sandwiched between electrodes. Whenan electric field is applied by the electrodes, the OLED material isbrought into an excited energy state, this energy state drops down bythe emission of photons, packets of light. Thus, each pixel of the OLEDdisplay can be controlled to emit light as needed to create a displayedimage.

Besides attractive picture quality, an OLED display device consumes lesspower than liquid crystal display technologies because it emits its ownlight and does not need backlighting. OLED displays are thin,lightweight, and may be able to be manufactured on flexible materialssuch as plastic.

Unlike liquid-crystal displays, OLEDs emit light that can be viewed fromany angle, similar to a television screen. As compared to LCDs, OLEDsare expected to be much less expensive to manufacture, use less power tooperate, emit brighter and sharper images, and “switch” images faster,meaning that videos or animation run more smoothly.

Recently, an effort has been made to create equipment and provideservices for manufacturing OLED screens. The potential OLED displaymarket includes a wide range of electronic products such as mobilephones, personal digital assistants, digital cameras, camcorders,micro-displays, personal computers, Internet appliances and otherconsumer products.

There is still a need for a thin, lightweight, flexible, bright,wireless display. Such a device would be self-powered, robust, include abuilt-in user-input mechanism, and ideally functional as a multipurposedisplay device for Internet, entertainment, computer, and communicationuse. The discovery of the OLED phenomenon puts this goal within sight.

However, there are still some technical hurdles left to be solved beforeOLED displays will realize their commercial potential. OLED's lightemitting materials don't have the lifespan some users may need.Presently, optimum performance in commercially viable volume productionis achievable only for small screens, around 3.5 inches square or less.Storage lifetimes of at least 5 years are typically required by mostconsumer and business products, and operating lifetimes of >20,000 hoursare relevant for most applications.

Organic-light-emitting-diode technology offers the prospect of flexibledisplays on plastic substrates and roll-to-roll manufacturing processes.One of the biggest challenges to the OLED display industry is fromcontamination by water and oxygen. The materials involved in smallmolecule and polymer OLEDs are vulnerable to contamination by oxygen andwater vapor, which can trigger early failure.

Recently, there has been activity in developing thin, flexible displaysthat utilize pixels of electro-luminescent materials, such as OLEDs.Such displays do not require any back lighting since each pixel elementgenerates its own light. Typically, the organic materials are depositedby spin-coating, vacuum deposition or evaporation. As examples, U.S.Pat. No. 6,395,328, issued to May, teaches an organic light emittingcolor display wherein a multi-color device is formed by depositing andpatterning layers of light emissive material. U.S. Pat. No. 5,965,979,issued to Friend, et al., teaches a method of making a light emittingdevice by laminating two self-supporting components, at least one ofwhich has a light emitting layer. U.S. Pat. No. 6,087,196, issued toStrum, et al., teaches a fabrication method for forming organicsemiconductor devices using ink jet printing. U.S. Pat. No. 6,416,885B1, issued to Towns et al., teaches an electro-luminescent devicewherein a conductive polymer layer between an organic light emittinglayer and a charge-injecting layer resists lateral spreading of chargecarriers to improve the display characteristics. U.S. Pat. No.6,420,200, issued to Yamazaki et al., teaches a method of manufacturingan electro-optical device using a relief printing or screen printingmethod. U.S. Pat. No. 6,402,579, issued to Pichler et al., teaches anorganic light-emitting device in which a multi-layer structure is formedby DC magnetron sputtering. U.S. Pat. No. 6,422,687, issued to Jacobson,teaches an electronically addressable microencapsulated ink and display.In accordance with the teachings of this reference, microcapsules areformed with a reflective side and a light absorbing side. Themicrocapsules act as pixels that can be flipped between the two states,and then keep that state without any additional power.

It is known to form an OLED layer by vacuum deposition, evaporation orspin coating. Thin layers of hole transport material and then electrontransport material are formed by these known methods over a grid ofanode electrodes. The anode electrodes are formed on a glass plate. Agrid of cathode electrodes is then placed adjacent to the electrontransport material supported by a second glass plate. Thus, the basicOLED organic stack is sandwiched between electrodes and glass platesubstrates. It is generally very difficult to form the electrodes withthe precise alignment needed for forming a pixilated display. This taskis made even more difficult in a multicolor display, where the OLEDpixels emitting, for example, red, green and blue, are formedside-by-side to fabricate a full color display. Because the OLEDmaterial and electrodes can be made transparent, it is possible to stackthe color OLED pixels on top of each other, allowing for a higher pixelpacking density and thus the potential for a higher resolution display.However, the electrode alignment issue still poses a problem. Typically,the well-known use of shadow masks are employed to fabricate the pixelcomponents. Aligning the shadow masks is difficult, and requires extremeprecision.

Currently, inkjet printing has gained ground as a promising fabricationmethod for making OLED displays. The core of this technology is verymature, and can be found in millions of computer printers around theworld. However, there are some disadvantages to the adapting of ink-jetprinting to OLED display fabrication. It is still difficult to lay downprecise layers of material using the spray heads of inkjet printers.Inkjet printing does not adequately overcome the problem of materialdegradation by oxygen and water vapor. Elaborate and expensive materialsand fabrication processes are needed to provide adequate encapsulationof the display elements to prevent early degradation of the OLEDmaterial due to water and oxygen ingress. As an attempt to solve thiscontamination problem, Vitex Systems, Sunnyvale, Calif., has developed abarrier material in which a monomer vapor is deposited on a polymersubstrate, and then the monomer is polymerized. A thin layer of aluminumoxide a few hundred angstroms thick is deposited on the polymerizedsurface. This process is repeated a number of times to form anencapsulation barrier over an OLED display. This elaborate encapsulationbarrier is an example of the effort taken to prevent water and oxygenfrom contaminating the easily degraded OLED films that form aconventional OLED display device. It is difficult to align displaypixel-sized electrodes and inkjet printed OLED material with theaccuracy needed to effect a high resolution display. Electrical shortsand the destruction of pixels result from the inclusion of minisculeforeign particles, requiring the use of expensive clean roommanufacturing facility for inkjet OLED fabrication. Accordingly there isa need for an improved fabrication method for forming OLED devices.

SUMMARY OF THE INVENTION

It is an object of the present invention to overcome the drawbacks ofthe prior art. In accordance with the present invention, a method isprovided for fabricating light active devices using field-attractivelight active particulate. It is another object of the present inventionto provide an OLED device that has a long shelf life, a long servicelife, is robust, effective and energy efficient. It is another object ofthe present invention to provide a method for fabricating an OLED deviceusing relatively simple manufacturing steps and relatively uncomplicatedfabrication equipment.

In accordance with the present invention, a method is provided forforming a light active device. A fluid carrier has light activeparticulate dispersed within it. A first electrode layer is provided anda layer of the fluid carrier dispersed with the light active particulateis laminated or coated on the first electrode layer. A second electrodelayer is provided on top of the laminated layer of the fluid carrierdispersed with the light active particulate. The light activeparticulate may comprise field reactive light active particulaterandomly dispersed within the fluid carrier. An aligning field isapplied between the first electrode and the second electrode to form adesired alignment of the field reactive light active particulate withinthe fluid carrier between the first electrode and the second electrode.The carrier may comprise a hardenable material. The carrier can behardened to form a hardened carrier for maintaining the desiredalignment of the light active particulate within the hardened carrier.

The first electrode layer may an x-electrode layer having x-electrodelines. The second electrode layer may comprise a y-electrode layerhaving y-electrode line disposed adjacent to the x electrode layer anddefining a gap therebetween so that pixel volumes are defined atintersections of respective x-electrode lines and y-electrode lines. Thelight active particulate can be effective for receiving through thecarrier electrical charges from the first electrode layer and the secondelectrode layer and generating photon emissions in response to receivingsaid electrical charges. The light active particulate can be effectivefor receiving a photon and separating electrical charges in response tothe received photon, the separated electrical charges being transferthrough the carrier to the first electrode layer and the secondelectrode.

In accordance with the present invention, an OLED device includes afirst electrode and a second electrode. The second electrode is disposedadjacent to the first electrode so that a gap is defined between them.Unlike the prior art, in accordance with the present invention, thinfilms of OLED material are not required to be formed. Instead, thepresent invention utilizes OLED particulate dispersed within aconductive carrier. The OLED particulate is dispersed within the carriermaterial, which is disposed within the gap between the electrodes. Whenan electric potential is applied to the electrodes, the electricalenergy passes through the carrier material raising the energy state ofthe OLED particulate, resulting in the emission of light.

The OLED particulate may comprise organic-layered particles, eachparticle includes a hole transport layer and an electron emitter layer.A heterojunction is formed at the interface between the hole transportlayer and the electron emitter layer. Each organic-layered particle mayalso include a blocking layer adjacent to the electron emitter layer andan emissive layer adjacent to the hole transport layer, thereby forminga stacked organic layered structure. The blocking layer is provided forfacilitating the flow of electrons from the electron emitter layer, andthe emissive layer is provided for facilitating the emission of photonswhen the energy state of the OLED particulate is raised.

In accordance with an aspect of the present invention, the OLEDparticulate comprises microcapsules. Each microcapsule includes aninternal phase and a shell. The internal phase and/or the shell includethe OLED material. The internal phase and/or the shell may also includea field reactive material. Depending on the OLED fabrication method andthe desire OLED characteristics, the field reactive material may be anelectrostatic material and/or a magnetically reactive material.

As is described further here in, the microcapsule composition may beeffective for enabling a “self healing” capability of the fabricatedOLED device. In this case, the microcapsule includes a composition thatcauses the microcapsule to rupture if electrical energy above athreshold is applied to the microcapsule. For example, if a particularmicrocapsule is aligned so the during use of the OLED device it becomesa short between the electrodes, or if the microcapsule is adjacent to adust particle or other foreign inclusion, creating such a short, when aelectric potential is applied between the electrodes energy exceeding apredetermined threshold will pass through the microcapsule causing thecapsule to rupture and disconnect the short. By this construction, themicrocapsule is automatically removed from the path of conduction ofelectrical energy in the event of a short.

In accordance with another aspect of the invention, the microcapsuleshell and/or internal phase may include a composition effective toprovide a barrier against degradation of the OLED material. The OLEDmicrocapsules are dispersed within a carrier fluid. This carrier fluidalso provides a barrier against the intrusion of substances whichdegrade the OLED material.

The OLED microcapsules can have constituent parts including at least oneof hole transport material, electron transport material, field reactivematerial, solvent material, color material, shell forming material,barrier material, desiccant material, and heat meltable material. Theconstituent parts form at least one internal phase and at least oneshell. The constituent parts are selected so as to have electricalcharacteristics that result in a preferred path of electrical conductionthrough the hole transport material and the electron transport material.By this construction, the microcapsule behaves as a pn junction uponapplication of an electrical potential to the first electrode and thesecond electrode.

The OLED device can be constructed of suitably chosen materials so thatthe carrier material is relatively less electrically conductive than theOLED particulate, this ensures that the OLED particulate offers a pathof less electrical resistance than the carrier material. Thus, theelectric potential applied to the electrodes will pass through thecarrier material, which has some electrical conductivity, and throughthe OLED particulate, which has relatively higher electricalconductivity. In this way, the preferred path of electrical conductionis through the OLED particulate. Likewise, the shell of the OLEDmicrocapsules is relatively less electrically conductive than the OLEDmaterial itself, so that the OLED material offers a path of lesselectrical resistance than the shell.

The typical OLED includes an OLED component that is a hole transportmaterial and an OLED component that is an electron transport material.In accordance with a formulation of the inventive microcapsules, theshell comprises an OLED component material that is either the holetransport material or the electron transport material, and the internalphase of the microcapsule includes the OLED component material that isthe other of the hole transport material and the electron transportmaterial. Depending on the desired optical qualities of the fabricatedOLED device, the carrier material can be selected so that it has opticalproperties during use of the OLED device that are transparent,diffusive, absorptive, and/or reflective to light energy. Thecomposition of the OLED particulate can be selected so that theelectrical characteristics of the OLED particulate includes, an electroor magneto rheological characteristic. This rheological characteristicis effective for causing the OLED particulate to move within the carrierand orient in response to an applied electrical or magnetic field.

In accordance with another composition of the OLED microcapsule, theinternal phase comprises OLED material and a magnetically reactivematerial disposed within a first shell. An electrolyte and a curablefluid material are disclosed surrounding the shell. A second shellencapsulates the first shell, the electrolyte and the curable material.In response to an applied magnetic field, the position of the firstshell is changeable relative to the second shell. Upon curing thecurable material, the position of the first shell relative to the secondshell is locked in place. As is described in detail herein, thismicrocapsule structure can be used to form capacitor/OLED microcapsuleswhich may be particularly effective for use in passive matrix displays.

In accordance with the present invention, a method for forming an OLEDdevice is provided. A top electrode and a bottom electrode are provideddefining a gap there between. Within the gap a field reactive OLEDparticulate is disposed randomly dispersed within a fluid carrier. Analigning field is applied between the top electrode and the bottomelectrode to form a desired orientation of the field reactive OLEDparticulate within the fluid carrier. The fluid carrier comprises aharden-able material. While the desired orientation of the fieldreactive OLED particulate is maintained, the carrier is cured to form ahardened support structure within which is locked in position the OLEDparticulate. The OLED particulate may comprise a dielectric OLEDmicrocapsule. The OLED particulate is formed by the steps of firstproviding a first particle comprised of a hole transport material. Thehole transport material has a net first electrical charge. A secondparticle comprised of an electron transport material is provided havinga net second electrical charge. The first electrical charge is ofopposite polarity from the second electrical charge. The first particleand the second particle are brought together to form a unified OLEDparticulate having a hole transport layer and an electron transportlayer forming a heterojunction between them. The first particle mayfurther include a photon-active layer. This photon-active layer may be alight emissive layer in which case the OLED forms a light emittingdevice, or a light receptive layer, in which case the OLED forms a lightdetecting device.

The OLED particulate is formed by microencapsulating an internal phasewithin a shell. The internal phase or the shell includes an OLEDmaterial and either the internal phase or the shell includes a fieldreactive material. The field reactive material comprises either or bothan electrostatic and a magnetically reactive material. In accordancewith another composition of the inventive microcapsule, the internalphase comprises an OLED emitter material and an OLED hole transportmaterial dispersed in solution. Color dyes may also be included withinthe internal phase. The solvent may be a fluid organic solvent. In orderto provide the alignment capabilities of the microcapsules, either theinternal phase or the shell may include a field reactive component.

In accordance with another aspect of the present invention, a stackedOLED device is provided. The inventive OLED device includes a first OLEDpixel layer comprised of a first layer electrode. A second layerelectrode is disposed adjacent to the first layer electrode. A firstlayer gap is defined between the electrodes. An OLED particulate isdispersed within a carrier and contained within the first layer gap. Atleast one subsequent OLED pixel layer is formed over the first OLEDpixel layer. Each subsequent OLED pixel layer includes a firstsubsequent layer electrode. A second subsequent layer electrode isdisposed adjacent to the first subsequent layer electrode defining asecond layer gap there between. An OLED particulate in a carriermaterial is disposed between the electrodes.

To achieve a full color OLED display, the OLED particulate of the firstOLED pixel layer emits light of a first wavelength range in response toa drive voltage being applied to the first layer electrode and thesecond layer electrode. Each subsequent OLED pixel layer emits light ofa different wavelength range in response to the driving voltage appliedto the respective electrode pairs so that an RGB color display can beformed.

Further, a dichromatic pixel layer can be formed adjacent to the lastsubsequent OLED pixel layer. The dichromatic pixel layer can be formedfrom a LCD display layer or from a dichromatic microcapsule displaylayer along the lines described in the 6,50,687 B1 patent issued toJacobson, This dichromatic pixel layer, as described fully herein,results in a display that can viewed in direct bright sunlight as wellas with improved contrast in indoor ambient lighting conditions.Further, additional subsequent OLED pixel layers can be provided whichemit light in additional color range having a color and/or lightintensity different from the color and/or light intensity of the otherOLED pixel layers.

Further, the inventive OLED device can be configured so as to detectlight impinging on a pixel grid formed in accordance with the presentinvention. In this case, the OLED particulate of a first OLED pixellayer emits a electrical energy in response to the reception of photonsand applies the electrical energy as a detectable signal to the firstand second layer electrodes. Further, a full color CCD-type camera canbe formed by tuning the wavelength range at which subsequent layers ofOLED pixels are photo reactive.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an embodiment of the inventive thin, lightweight,flexible, bright wireless display having components capable of beingmanufactured by the inventive display fabrication method, showing thesimultaneous display of mapped hyperlinked content, a videophone streamand a broadcast TV stream;

FIG. 2 illustrates a particle of OLED material for being dispersed in acarrier fluid in accordance with the inventive display fabricationmethod;

FIG. 3 illustrates an inventive microcapsule comprised of an internalphase of OLED material encapsulated within a polymer shell;

FIG. 4 illustrates an inventive dielectric microcapsule comprised of aninternal phase of OLED material encapsulated within a polymer shell;

FIG. 5 illustrates an inventive microcapsule comprised of a firstmicrocapsule including an internal phase of OLED material and magneticmaterial, along with a mixture of electrolyte and uncured monomer, allencapsulated within a polymer shell;

FIG. 6 illustrates an inventive microcapsule comprised of an internalphase of OLED material encapsulated within a double-wall shell, eachwall having a composition selected for imparting a desired electrical,optical, magnetic and/or mechanical property to the microcapsule;

FIG. 7 illustrates an inventive microcapsule comprised of an internalphase consisting of a mixture of OLED material with other components soas to tailor the electrical, optical, magnetic and/or mechanicalproperty of the microcapsule;

FIG. 8 illustrates an inventive microcapsule comprised of a firstmicrocapsule including an internal phase comprised of an OLED material,and a corrosion barrier material, all encapsulated within a polymershell;

FIG. 9 illustrates an inventive microcapsule comprised of a multi-walledmicrocapsule structure wherein layers of corrosion barrier material areencapsulated within polymer shells with an internal phase of OLEDmaterial;

FIG. 10 illustrates an inkjet-type or other nozzle fabrication methodfor forming a layer of OLED microcapsules dispersed within a lightcurable monomer carrier;

FIG. 11 illustrates a layer of OLED microcapsules fixed within a curedmonomer barrier disposed between a top electrode and a bottom electrode;

FIG. 12 illustrates sealed fabrication stations for forming a barrierprotected OLED microcapsule display stratum;

FIG. 13 illustrates an inventive display fabrication line using modularprinters for forming various stratum of a thin, lightweight, flexiblewireless display;

FIG. 14 illustrates a highly organized OLED microcapsule structureformed in accordance with the inventive OLED device fabrication method;

FIG. 15 illustrates a chain structure of OLED microcapsules formed inaccordance with the inventive OLED device fabrication method;

FIG. 16 illustrates a full color OLED display formed in accordance withthe inventive OLED device fabrication method;

FIG. 17 illustrates a layer of conductive microcapsules for forming anelectrode layer in accordance with the inventive device fabricationmethod;

FIG. 18 illustrates the formation of OLED microcapsule chains formed onan electrode layer;

FIG. 19 illustrates the formation of OLED microcapsule chains formedbetween top and bottom electrode layers;

FIG. 20 illustrates the formation of OLED microcapsule chains within acured carrier for forming a corrosion barrier;

FIG. 21 illustrates a full color display formed in accordance with theinventive OLED device fabrication method;

FIG. 22 illustrates step one of an embodiment of the inventive OLEDdevice fabrication method;

FIG. 23 illustrates step two of an embodiment of the inventive OLEDdevice fabrication method;

FIG. 24 illustrates step three of an embodiment of the inventive OLEDdevice fabrication method;

FIG. 25 illustrates step four of an embodiment of the inventive OLEDdevice fabrication method;

FIG. 26 illustrates step five of an embodiment of the inventive OLEDdevice fabrication method;

FIG. 27 illustrates step six of an embodiment of the inventive OLEDdevice fabrication method;

FIG. 28 shows a magnetically reactive OLED microcapsule for forming acapacitor OLED microcapsule with the aligning field turned off;

FIG. 29 shows a magnetically reactive OLED microcapsule for forming acapacitor OLED microcapsule with the magnetic aligning field turned onwith uncured electrolyte mixture;

FIG. 30 shows a magnetically reactive OLED microcapsule for forming acapacitor OLED microcapsule with the magnetic aligning field turned onwith cured electrolyte mixture;

FIG. 31 shows a pixel comprised of a chain of capacitor OLED beingcharged by a charging voltage;

FIG. 32 shows a pixel comprised of a chain of capacitor OLED beingtriggered for light emission by a trigger voltage;

FIG. 33 shows OLED microcapsules randomly dispersed within a fluid buthardenable carrier fluid;

FIG. 34 shows OLED microcapsule chains aligned within an appliedaligning field formed within unhardened carrier fluid;

FIG. 35 shows OLED microcapsule chains aligned within an appliedaligning field held in alignment within hardened carrier;

FIG. 36 shows the OLED microcapsule structure shown in FIG. 35 with adrive voltage applied and light being emitted from the OLED microcapsulechains;

FIG. 37 illustrates a method for forming an OLED particulate having ahole transport layer and an electron transport layer;

FIG. 38 illustrates a method for forming an encapsulated OLEDparticulate;

FIG. 39 illustrates a first step in forming a multi-layered OLEDparticulate;

FIG. 40 illustrates a second step in forming a multi-layered OLEDparticulate;

FIG. 41 illustrates a third step in forming a multi-layered OLEDparticulate;

FIG. 42 schematically shows a full-color OLED display constructed inaccordance with the present invention, and having a dichromatic displaylayer for improving the display contrast, power efficiency and forproviding display viewing in bright sunlight;

FIG. 43 schematically shows the full-color OLED display shown in FIG.42, with the dichromatic pixels oriented for reflecting emitted OLEDlight;

FIG. 44 schematically shows the full-color OLED display shown in FIG.42, showing the relative strength of reflected light depending on thedichromatic pixel orientations;

FIG. 45 shows magnetically-active OLED microcapsules randomly dispersedwithin a fluid but hardenable carrier fluid along with desiccantparticulate;

FIG. 46 shows the magnetically-active OLED microcapsule chains alignedwithin an applied magnetic aligning field within the unhardened carrierfluid;

FIG. 47 shows the magnetically-active OLED microcapsule chains alignedwithin the applied magnetic aligning field held in position within thehardened carrier;

FIG. 48 shows the magnetically-active OLED microcapsule structure withlight being emitted from the OLED microcapsule chains;

FIG. 49 schematically illustrates a full color OLED display having highintensity visible light display layers and an infrared display layer;

FIG. 50 shows an OLED display layer and a liquid crystal display layer;

FIG. 51 shows an inventive OLED display fabricated with thin films oforganic material with photodetection elements and photodetection pixelelements;

FIG. 52 shows an OLED microcapsule wherein the shell is slightly lessconductive than the encapsulated OLED material;

FIG. 53 shows an OLED microcapsule wherein the OLED material isencapsulated along with an electrolyte and a magnetic inner microcapsulehaving an electrically insulative shell;

FIG. 54 shows an OLED microcapsule wherein the OLED material and thehole transport material are contained in solution within a conductiveshell;

FIG. 55 shows the OLED microcapsules shown in FIG. 54 including amagnetically active material and color dye in the inner phase and heatmeltable material in the shell;

FIG. 56 illustrates the OLED microcapsule shown in FIG. 54 used forcreating a general lighting or display back lighting OLED device;

FIG. 57 illustrates a transparent, flexible OLED display fabricated foruse as part of a vehicle windshield;

FIG. 58 is a block diagram showing the basic components of an activewindshield display system using an OLED display;

FIG. 59 illustrates an OLED light emissive element;

FIG. 60 shows the OLED light emissive element having a conventionallight bulb form factor;

FIG. 61 illustrates an OLED device fabricated using light emissivelayers and light detecting layers;

FIG. 62 illustrates stereoscopic goggles having OLED device elements;

FIG. 63 illustrates a flexible OLED display having a curvature thecompensates for the human eye's range of motion;

FIG. 64 illustrates a flexible OLED display having optical lens elementsfor focusing emitted light at the appropriate physical location within ahuman eye;

FIG. 65 illustrates a wraparound visor having a curved, flexible OLEDdisplay and speakers;

FIG. 66 illustrates a wall of a house having an inventive OLED displaywindow, the window being driven so as to be transparent with treesoutside the house visible through the window;

FIG. 67 illustrates the wall of a house having the inventive OLEDdisplay window, the window being driven so as to display multiplesimultaneous video stream including video phone communication, Internetweb page and a television program; and

FIG. 68 illustrates the wall of a house having the inventive OLEDdisplay window, the window being driven so as to be a mirror.

DETAILED DESCRIPTION OF THE INVENTION

For purposes of promoting an understanding of the principles of theinvention, reference will now be made to the embodiments illustrated inthe drawings and specific language will be used to describe the same. Itwill nevertheless be understood that no limitation of the scope of theinvention is thereby intended, there being contemplated such alterationsand modifications of the illustrated device, and such furtherapplications of the principles of the invention as disclosed herein, aswould normally occur to one skilled in the art to which the inventionpertains.

FIG. 1 illustrates an embodiment of the inventive thin, lightweight,flexible, bright wireless display having components capable of beingmanufactured by the inventive display fabrication method, showing thesimultaneous display of mapped hyperlinked content, a videophone streamand a broadcast TV stream. FIG. 1 illustrates an embodiment of aninventive thin, lightweight, flexible, bright, wireless display showingthe simultaneous display of three received display signal. The inventivethin, lightweight, flexible, bright, wireless display includes aflexible substrate 24 to provide a support structure upon whichcomponents can be manufactured by a fabrication method. As described inthe co-owned U.S. patent application Ser. No. 10/234,302, entitled “AThin, Lightweight, Flexible, Bright, Wireless Display”, the disclosureof which is incorporated by reference herein, a unique and effectivemethod for transmitting display information to a single or multipledisplays enables such displays to not have to have substantial onboardstorage or processing power. In accordance with this aspect of theinvention, the energy drain, bulk, weight and cost normally associatedwith such devices is avoided, and the durability and convenience of thedisplay is increased. Further, as shown schematically in FIG. 1,multiple streams of display information can be simultaneously receivedand displayed. For example, broadcast video content such as a televisionprogram may be shown at a first portion of the display, personalizedvideo content, such as a videophone conversation may be shown at asecond portion and a web page, including mapped hyperlink content, maybe shown at a third portion. Most of the processing, networking, signaltuning, data storage, etc., etc., that it takes to create such a set ofdisplayed content streams is not performed by the inventive wirelessdisplay. Other devices, such as a centralized computer, A/V or gatewaydevice perform these functions thus allowing the opportunity for theinventive display to have tremendous mobility and convenience.

FIG. 1 illustrates an embodiment of the inventive thin, lightweight,flexible, bright wireless display having components capable of beingmanufactured by the inventive fabrication method, showing thesimultaneous display of mapped hyperlinked content, a videophone streamand a broadcast TV stream. In accordance with the present invention, athin, lightweight, flexible, bright wireless display is obtained havingcomponents capable of being manufactured by the inventive fabricationmethod. The present invention enables a low cost, flexible, robust, fullcolor video display to be obtained. This wireless display is capable ofreceiving multiple display information signals and displaying thesimultaneous screens of the received display information inre-configurable formats. A relatively simple signal receiving andprocessing circuit, using, for example, a digital signal processor suchas those available from Texas Instruments, Texas or Oxford Microdevices,Connecticut, enables multiple video and still image screens to bedisplayed. An inventive manufacturing method described herein and in theco-owned patent application entitled “Printer and Method forManufacturing Electronic Circuits and Displays” (incorporated byreference herein) enables the inventive wireless display to befabricated at low cost and with the advantageous features describedherein. As described in more detail herein, a flexible substrateprovides a support structure upon which components can be manufacturedby a fabrication method. A display stratum includes light emittingpixels for displaying information. The light emitting pixels are formed,by printing a pixel layer of light-emitting conductive polymer. Anelectronic circuit stratum includes signal transmitting components fortransmitting user input signals to a display signal generating devicefor controlling display information transmitted from the display signalgenerating device. Signal receiving components receive the displayinformation transmitted from the display signal-generating device.Display driving components drive the display layer according to thereceived display information. A user input stratum receives user inputand generates the user input signals. A battery stratum provideselectrical energy to the electronic circuit stratum, the user inputstratum and display stratum components. The signal receiving componentsmay include first radio frequency receiving components for receiving afirst display signal having first display information carried on a firstradio frequency and second radio frequency receiving components forreceiving a second display signal having second display informationcarried on a second radio frequency. The display driving components mayinclude signal processor components for receiving the first displaysignal and the second display signal and generating a display drivingsignal for simultaneously displaying the first display information at afirst location on the display stratum and the second display informationat a second location on the display stratum. At least some of thecomponents in the battery, display, user input and electronic circuitstratums are formed by printing electrically active material to formcircuit elements including resistors, capacitors, inductors, antennas,conductors and semiconductor devices.

The inventive thin, lightweight, wireless display includes OLAMfabrication, such as that described herein. In accordance with thepresent invention, microcapsule 10 particulate are randomly dispersedwithin a monomer carrier fluid 12 that is injected or otherwise disposedbetween two electrodes 14. The term particulate can refer to particlesof material or microcapsules 10. The microcapsules 10 may includeadditives that impart rheological properties. The microcapsules 10 formchains between the electrodes 14 when a voltage is applied. Holding thevoltage to keep the chains formed, the carrier fluid 12 is polymerizedand the OLAM microcapsule chains locked into alignment between theelectrodes 14. The thus formed OLAM pixels emit light (or detect orconvert light into electricity). The problem of contamination of theOLAM material is the major factor limiting the display life span, andthus is a bar to commercial success. The inventive fabrication methodresults in the corrosion sensitive OLAM material being protected by themicrocapsule shell and the cured carrier 12. The pixel alignment isautomatic, since the microcapsule chains are formed only between theelectrodes 14. This pixel array structure also greatly limits cross talkbetween pixels and the optical properties of the cured monomer can becontrolled to improve contrast, display brightness, transparency, etc.

Solar cell components or layers can be used to “recycle” the energyemitted by the OLED emitters. Some of the emitted and ambient lightenergy impinges on the solar cells and generate electricity. This, alongwith the inventions described herein and the sheet battery described inthe above-referenced co-owned Patent Applicant entitled “Printer andMethod for Manufacturing Electronic Circuits and Displays”, can enablelightweight, relatively inexpensive, dichromatic newspapers (asdescribed herein in FIG. 1) that recharge in sunlight (or even indoorambient light) to enable full-color emissive video display.

FIG. 2 illustrates a particle of OLED material for being dispersed in acarrier fluid 12 in accordance with the inventive display fabricationmethod. A typical OLED organic stack consists of a layer of holetransport material and a layer of electron transport material. In theconventional art, these layers are formed by spin coating, vacuumdeposition or inkjet printing. In accordance with the present invention,the OLED material is provided as particulate dispersed within a carrier12 material. The carrier 12 material with the dispersed particulate isdisposed between electrodes 14. Electrical potential applied to theelectrodes 14 causes light emission to occur within the OLEDparticulate. In accordance with the present invention, the OLEDphenomenon can be used to create general or specialty lighting devices,monochrome or color displays, stereoscopic vision aids, digital maps andnewspapers, advanced vehicle windshields and the like. Also, theparticulate can be organic light active material (“OLAM™”) that iscapable of generating a flow of electrons in response to impinging lightenergy. This phenomenon can be used to create photodetectors, cameras,solar cells and the like. In this application, where appropriate, theterm OLED can mean a light emissive or a light detective materialconfiguration.

FIG. 3 illustrates an inventive microcapsule 10 comprised of an internalphase of OLAM material encapsulated within a polymer shell. To create apath of least resistance through the OLED material, the shellcomposition is selected to be less conductive than the OLED material.

FIG. 4 illustrates an inventive electro-statically active microcapsule10 comprised of an internal phase of OLED material encapsulated within apolymer shell. The shell is composed of a material that can be orientedby the application of an electric field. The electrical properties ofthe shell enable the microcapsules 10 to be aligned into a desiredformation within a fluid carrier 12 in response to an applied electricfield.

FIG. 5 illustrates an inventive microcapsule 10 comprised of a firstmicrocapsule 10 including an internal phase of OLED material andmagnetic material, along with a mixture of electrolyte and uncuredmonomer, all encapsulated within a polymer shell. The magneticproperties of the magnetic material enable the microcapsules 10 to bealigned into a desired formation within a fluid carrier 12 in responseto an applied magnetic field.

FIG. 6 illustrates an inventive microcapsule 10 comprised of an internalphase of OLED material encapsulated within a double-wall shell, eachwall having a composition selected for imparting a desired electrical,optical, magnetic and/or mechanical property to the microcapsule. Inaccordance with the present invention, the OLED particulate comprisesmicrocapsules 10. For example, the microcapsule 10 includes an internalphase and a shell that is composed of material selected according to adesired combination of electrical, mechanical, optical and magneticproperties. The internal phase and/or the shell may include the OLEDmaterial. The internal phase and/or the shell may also include a fieldreactive material. Depending on the OLED fabrication method and thedesire OLED characteristics, the field reactive material may be anelectrostatic material and/or a magnetically reactive material. Themicrocapsule 10 composition may be effective for enabling a “selfhealing” capability of the fabricated OLED device. In this case, themicrocapsule 10 includes a composition that causes the microcapsule 10to rupture if electrical energy above a threshold is applied to themicrocapsule. A heat meltable material that heats up when electricalenergy above a threshold is applied can be incorporated as themicrocapsule shell. For example, if a particular microcapsule 10 ends uppositioned so that during use of the OLED device it becomes a shortbetween the electrodes 14, or if the microcapsule 10 is adjacent to adust particle or other foreign inclusion, creating such a short, when anelectric potential is applied between the electrodes 14, energyexceeding a predetermined threshold will pass through the microcapsule10 causing the capsule to rupture and disconnect the short. By thisconstruction, the microcapsule 10 is automatically removed from the pathof conduction of electrical energy in the event of a short.

FIG. 7 illustrates an inventive microcapsule 10 comprised of an internalphase consisting of a mixture of OLED material with other components soas to tailor the electrical, optical, magnetic and/or mechanicalproperty of the microcapsule. The other components can be fieldreactive, such as magnetic or electrostatically reactive materials forimparting orientation and aligning properties. Heat expandable materialscan be included to provide the microcapsule 10 with the ability to burstin response to an electrical short to disconnect the microcapsule 10 andovercome the electrical short. Colorants, such as dyes and coloredparticles can be included to tune the light emitted from themicrocapsule. Desiccant material can be included to provide protectionagainst contamination of the OLED material.

FIG. 8 illustrates an inventive microcapsule 10 comprised of a firstmicrocapsule 10 including an internal phase comprised of an OLEDmaterial, and a corrosion barrier material, all encapsulated within apolymer shell. In accordance with this aspect of the invention, themicrocapsule shell and/or internal phase may include a compositioneffective to provide a barrier against degradation of the OLED material.The OLED microcapsules 10 are dispersed within a carrier fluid 12. Thiscarrier fluid 12 also provides a barrier against the intrusion ofsubstances which degrade the OLED material.

FIG. 9 illustrates an inventive microcapsule 10 comprised of amulti-walled microcapsule 10 structure wherein layers of corrosionbarrier material are encapsulated within polymer shells with an internalphase of OLED material. As in the microcapsule 10 shown in FIG. 7,within the shell of the microcapsule 10 other components can be includedthat are field reactive, such as magnetic or electro-statically reactivematerials for imparting orientation and aligning properties. Heatexpandable materials can be included to provide the microcapsule 10 withthe ability to burst in response to an electrical short to disconnectthe microcapsule 10 and overcome the electrical short. Colorants, suchas dyes and colored particles can be included to tune the light emittedfrom the microcapsule. Desiccant material can be included to provideprotection against contamination of the OLED material.

FIG. 10 illustrates an inkjet-type or other nozzle 36 fabrication methodfor forming a layer of OLED microcapsules 10 dispersed within a lightcurable monomer carrier 12. OLED microcapsules 10 dispersed in anuncured monomer carrier fluid 12 can be utilized with ink-jet printingtechnology to create a film of OLED microcapsules 10 contained withflexible cured monomer. The inkjet-type or other nozzle fabricationtechnique can be utilized to form controlled OLED deposition, with theOLED contained within a curable carrier 12. As is described elsewhereherein, desiccant particulate can be included within the carrier 12 toenhance the protection of the OLED material.

FIG. 11 illustrates a layer of OLED microcapsules 10 fixed within acured monomer barrier disposed between a top electrode 14 and a bottomelectrode 14. The cured monomer and the shell of the microcapsules 10provide a barrier to contamination from water vapor and oxygen. The OLEDdevice can be constructed of suitably chosen materials so that thecarrier 12 material is relatively less electrically conductive than theOLED particulate, this ensures that the OLED particulate offers a pathof less electrical resistance than the carrier 12 material. Thus, theelectric potential applied to the electrodes 14 will pass through thecarrier 12 material, which has some electrical conductivity, and throughthe OLED particulate, which has relatively higher electricalconductivity. In this way, the preferred path of electrical conductionis through the OLED particulate. Likewise, the shell of the OLEDmicrocapsules 10 is relatively less electrically conductive than theOLED material itself, so that the OLED material offers a path of lesselectrical resistance than the shell. Field-attractive microcapsules 10containing OLED material randomly dispersed within a monomer carrierfluid 12 are injected or otherwise disposed between two electrodes 14.The microcapsules 10 may include additives that impart electro ormagneto rheological-type properties. When used for a pixilated displaylayer, the microcapsules 10 form chains between the electrodes 14 when aaligning field is applied. Holding the aligning field to keep the chainsformed, the carrier fluid 12 is polymerized and the OLED microcapsulechains are locked into alignment between the electrodes 14.

The problem of contamination of the OLED material is the major factorlimiting the display life span, and thus is a bar to commercial success.The inventive fabrication method results in the corrosion sensitive OLEDmaterial being protected by the microcapsule shell and the cured carrier12, and the pixel alignment is automatic, since the microcapsule chainsare formed only between the electrodes 14 or where the aligning field isapplied. This pixel array structure also greatly limits cross talkbetween pixels and the optical properties of the cured carrier 12 can becontrolled to improve contrast, display brightness, transparency, etc.The OLED particulate in a carrier 12 disposed between two or moreelectrodes 14 can be utilized to create roll-to-roll sheets of displaysor lights, used as “filament” in a light bulb, used to form solar cells,solar cell housing shingles, light detectors, cameras, vision aides,heads-up display windshields and the like. This OLAM construction caneven be formed as fibers for light emitting flooring, wall coverings,specialty lighting, clothing, shoes, building materials, furniture, etc.

FIG. 12 illustrates sealed fabrication stations 22 for forming a barrierprotected OLED microcapsule 10 display stratum. The microcapsules 10 aredispersed in a carrier fluid 12. The upper and lower plates 16, controlthe intensity of the attraction toward the flexible substrate 24 andsheet electrode 14. Seals 18 keep out water and air, using a vacuumairlock. The curing station 20 cures the carrier fluid 12 into aflexible water and oxygen barrier. The microcapsules 10 can be forforming emitters, detectors, various electronic circuit elements (asdescribed in the referenced co-owned patent application). Themicrocapsules 10 may also be for adding other mechanical (structure,expansive, meltable, desiccant, etc.), optical (reflective, diffusive,opaque, colorant, etc.), electrical (conductive, resistive,semi-conductive, insulative, etc.). The upper and lower plates 16 arecontrolled to vary the attractive and/or aligning field and createcontrolled accumulations and alignments of the microcapsules 10. Theviscosity of the fluid can also be controlled to control theaccumulations of microcapsules 10 (for three-dimensional buildup,control spread of pixels, etc.). As an example, lower viscosity carrierfluid 12 with an agitator may be preferred. There can be, for example,two simultaneously applied aligning fields, magnetic and electrostatic.A mix of microcapsules 10 can be dispersed, (e.g., magnetically andconductive OLED microcapsules 10 and electro-statically conductiveinsulators for creating a more controllable path of least resistance).

FIG. 13 illustrates an inventive display fabrication line using modularprinters for forming various stratum of a thin, lightweight, flexiblewireless display. Display fabrication line uses mix of differentfabrication stations 22. Examples of fabrication stations 22 can befound in co-owned U.S. patent application Ser. No. 10/234,301 entitled“Printer and Method for Manufacturing Electronic Circuits and Displays”.The various layers of a display include battery, electronic circuit,user input and display stratums are formed at different fabricationstations 22. In accordance with the present invention, fabricationstations 22 for forming an OLED light emissive device is provided. A topelectrode 14 and a bottom electrode 14 define a gap there between.Disposed within the gap, field reactive OLED particulates are randomlydispersed within a fluid carrier 12. Depending on the device beingfabricated, an aligning field may be applied between the top electrode14 and the bottom electrode 14 to form a desired orientation of thefield reactive OLED particulate within the fluid carrier 12 between thetop electrode 14 and the bottom electrode 14. The carrier 12 comprises ahardenable material, such as a light-curable liquid monomer. The carrier12 is cured to form a hardened carrier 12 for maintaining the desiredorientation of the field reactive OLED particulate within the hardenedcarrier 12. The OLED particulate may comprise a dielectric OLEDmicrocapsule 10 or other OLED-based structure that is capable of formingchains between the electrodes 14.

Depending on the quality of the barrier created by the inventivefabrication method, there may be no need for additional barrier layers30 other than substrates 24 since cured carrier 12 and microcapsuleshells protect OLED material from water vapor and oxygen. Alternatively,addition barrier layers 30, including monomer, polymer, ceramic or thinmetal layers can be included in the structure as needed to protect theOLED material from contamination. Each color layer can be built on theprevious by fabrication method. The conductors 26 that make up the pixelelectrodes 14 can also be used to fabricate the OLED microcapsule 10structure. In this case the substrate 24 and pixel electrode 14 gridbecome integral parts of the completed OLED device. Further, theelectric field created by applying voltage to the electrodes 14 can beused to align the OLED microcapsules 10 in chains as shown elsewhereherein. The mechanism for this alignment is similar to the phenomenonthat causes electro-rheological fluids to form chains within a carrierfluid 12. In this case, the OLED microcapsule 10 or the OLED particleitself includes the appropriate material component that enables theelectro-rheological effect. In addition, or alternatively, magneticmaterial can be employed with a magnetic field being applied as thealigning field. The light emitted from the OLED material when energizedby the applied voltage can be used cure the monomer surrounding themicrocapsules 10. Thus, the voltage applied to the electrodes 14 duringdevice fabrication are utilized to form the pixel orientation andsimultaneously cure the barrier material.

FIG. 14 illustrates a highly organized OLED microcapsule 10 structureformed in accordance with the inventive OLED device fabrication method.Pixels can be controlled down to the microcapsule 10 size, spaced apartas needed. The conductive shell having a semi-insulative orsemi-conductive electrical property. The insulative or semiconductorshell creates a preferred path for the electron movement. By controllingthe conductivity of the cured carrier fluid 12, the preferred path canbe more pronounced through the OLED material.

FIG. 15 illustrates a chain structure of OLED microcapsules 10 formed inaccordance with the inventive OLED device fabrication method. Chains ofmicrocapsules 10 can be formed encased in opaque cured carrier 12,creating more intense light and defined pixels, or the carrier 12 can bean optical diffusion layer to create a mixing of light from adjacentpixels. In accordance with the present invention, an OLED deviceincludes a first electrode 14 and a second electrode 14. The secondelectrode 14 is disposed adjacent to the first electrode 14 so that agap is defined between them. An OLED particulate is dispersed within acarrier 12 material, which is disposed within the gap. When an electricpotential is applied to the electrodes 14, the electrical energy passesthrough the carrier 12 material raising the energy state of the OLEDparticulate, resulting in the emission of light. The typical OLEDincludes an OLED component that is a hole transport material and an OLEDcomponent that is an electron transport material. In accordance with aformulation of the inventive microcapsules 10, the shell comprises anOLED component material that is either the hole transport material orthe electron transport material, and the internal phase of themicrocapsule 10 includes the OLED component material that is the otherof the hole transport material or the electron transport material.Depending on the desired optical qualities of the fabricated OLEDdevice, the carrier 12 material can be selected so that it has opticalproperties during use of the OLED device that are transparent,diffusive, absorptive, and/or reflective to light energy.

FIG. 16 illustrates a full color OLED display formed in accordance withthe inventive OLED device fabrication method. The inventive microcapsule10 fabrication is used to create a full color emissive display. Pixelscan be controlled down to the microcapsule 10 size, spaced apart asneeded. The conductive shell can have a semi-conductive, conductive oran insulative over shell. The composition creates a preferred path forthe electron movement. By controlling the conductivity of the curedcarrier fluid 12, the preferred path can be more pronounced. Theinventive OLED device includes a first OLED pixel layer comprised of afirst layer electrode 14.

A second layer electrode 14 is disposed adjacent to the first layerelectrode 14. A first layer gap is defined between the electrodes 14. AnOLED particulate is dispersed within a carrier 12 and contained withinthe first layer gap. At least one subsequent OLED pixel layer is formedover the first OLED pixel layer. Each subsequent OLED pixel layerincludes a first subsequent layer electrode 14. A second subsequentlayer electrode 14 is disposed adjacent to the first subsequent layerelectrode 14 defining a second layer gap there between. An OLEDparticulate in a carrier 12 material is disposed between the electrodes14. To achieve a full color OLED display, the OLED particulate of thefirst OLED pixel layer emits light of a first wavelength range inresponse to a drive voltage being applied to the first layer electrode14 and the second layer electrode 14. Each subsequent OLED pixel layeremits light of a different wavelength range in response to the drivingvoltage applied to the respective electrode 14 pairs so that an RGBcolor display can be formed.

FIG. 17 illustrates a layer of conductive microcapsules 10 for formingan electrode 14 layer in accordance with the inventive devicefabrication method. The buildup of microcapsule 10 layers may occur insuccessive fabrication steps. The conductor 26 may be microencapsulated,or just a field attractive material. For example, a ferrous metal powdercan be magnetically attracted to form one or more of the conductors. TheOLED microcapsule 10 can be electrostatic or magnetically attractive.The carrier 12 substrate 24 has to pass the applied field. The carrierfluid 12 is heat or light hardenable by light emitted from a curinglight source 28 to lock the microcapsules 10 in place. Alternatively,the carrier fluid 12 can be a plastic material capable of beinginjection molded, or a multi-part mixture such as an epoxy, a conductivepowder and a hardener.

FIG. 18 illustrates the formation of OLED microcapsule chains formed onan electrode 14 layer. Conductive pixels can be etched into optomagneticor optoelectric coating to improve resolution. Or the location of thepixel that is energized can be controlled by light or laser pulse orother mechanism. The light curable polymer can be cured to a desireddepth to capture the microcapsules 10 that have been attracted, and thuslock in, for example, a microcapsule chain having a desired length.

FIG. 19 illustrates the formation of OLED microcapsule chains formedbetween top and bottom electrode layers. The electrodes 14 can be formedin previous fabrication steps, and may be attracted by a mechanism otherthan the mechanism that orients the OLED particulate.

FIG. 20 illustrates the formation of OLED microcapsule chains within acured carrier 12 for forming a corrosion barrier. The substrate 24 uponwhich the microcapsules 10 are printed may be a multi-layeredcomposition of polymer, cured monomer, ceramic and fiber, such as glass,creating a durable, flexible substrate 24 that is also a barrier tocorrosion for the OLED (as is the microcapsule shell and the curedcarrier fluid 12). The conductors 26 that make up the pixel electrodes14 can also be used to apply the aligning field used to fabricate theOLED microcapsule 10 structure.

FIG. 21 illustrates a full color display formed in accordance with theinventive OLED device fabrication method. Depending on the quality ofthe barrier created by the inventive fabrication method, there may be noneed for additional barrier layers 30 other than substrates 24 sincecured carrier 12 and microcapsule shells protect the OLED material fromwater vapor and oxygen. Alternatively, additional barrier layers 30,including monomer, polymer, ceramic, fiber, desiccant and/or thin metallayers can be included in the structure as needed to protect the OLEDmaterial from contamination. Each color layer can be built on theprevious, by a fabrication station. The conductors 26 that make up thepixel electrodes 14 can also be used to fabricate the OLED microcapsulestructure. In this case, the substrate 24 and pixel electrode gridbecome integral parts of the completed OLED device. The electric fieldcreated by applying voltage to the electrodes 14 can be used to alignthe OLED microcapsules 10 in chains as shown elsewhere herein. Themechanism for this alignment is similar to the phenomenon that causeselectro-rheological fluids to form chains within a carrier fluid 12. Inthis case, the OLED microcapsule 10 or the OLED particle itself includesthe appropriate material component that enables the Theological effect(i.e., the movement of the OLED particulate within the carrier). Inaddition, or alternatively, magnetic material can be used with amagnetic field being applied as the aligning field. The light emittedfrom the OLED material when energized by the applied driving voltage canbe used to cure the monomer surrounding the microcapsules 10. Thus, thevoltage applied to the electrodes 14 during device fabrication can beutilized to form the pixel orientation and simultaneously cure thebarrier material.

FIGS. 22-27 illustrate the steps for forming an OLED device inaccordance with an embodiment of the present invention. FIG. 22illustrates step one of an embodiment of the inventive OLED devicefabrication method. Step One: Provide Top and Bottom FlexibleSubstrates. Step Two: Form Barrier layers 30 on Top and Bottom FlexibleSubstrates 24 (FIG. 23). Step Three: Form Top and Bottom Electrodes 14on Barrier layer 30 (FIG. 24). Step Four: Fill Void between Top andBottom Electrode 14 with OLED microcapsules 10 dispersed in uncuredcarrier fluid 12 (FIG. 25). Step Five: Apply potential from an aligningfield source 32 to electrodes 14 to organize OLED microcapsules 10 intochains (FIG. 26). Step Six: Cure carrier 12 to lock OLED microcapsulechains between the electrodes 14 to form pixels (FIG. 27). Thecomposition of the OLED particulate can be selected so that thecharacteristics of the OLED particulate includes an electro or magnetotheological characteristic. This rheological characteristic is effectivefor causing the OLED particulate to orient in an applied aligning field.

FIG. 28 shows a magnetically reactive OLED microcapsule 10 for forming acapacitor OLED microcapsule 10 with the aligning field from an aligningfield source 32 turned off. An OLED microcapsule 10 is formed having acapacitor capability. An OLED material internal phase is encapsulatedwithin a first shell. An electrolyte surrounds the first shell and asecond shell encapsulates the first shell and the electrolyte. The OLEDmaterial internal phase includes a field reactive material. The fieldreactive material comprises at least one of a magnetically reactivematerial and an electrically reactive material effective to orient theOLED microcapsule 10 within an aligning field applied from the aligningfield source 32. By this construction, OLED material and fieldattractive material, such as magnetic material, are microencapsulatedwithin an electrically conductive shell, forming an OLED/Mag internalcore. The OLED/Mag internal core is microencapsulated along with amixture of electrolyte and light curable monomer liquid phase within asecond electrically conductive shell. The microcapsule shell material isselected to have the appropriate breakdown voltage at which chargeconduction occurs. The microcapsules 10 act as capacitor elements thatare charged up with a charging voltage. A trigger voltage is thenapplied when the OLED pixel is to emit light.

FIGS. 28-30 illustrate the formation of an OLED/Capacitor microcapsule.OLED material and field attractive material, such as magnetic material,are microencapsulated within an electrically conductive shell, formingan OLED/Mag core. The OLED/Mag core is microencapsulated along with amixture of electrolyte and light curable monomer liquid phase within asecond electrically conductive shell. The microcapsule shell material isselected to have the appropriate breakdown voltage at which chargeconduction occurs. FIG. 29 shows a magnetically reactive OLEDmicrocapsule 10 for forming a capacitor OLED microcapsule 10 with themagnetic aligning field turned on with uncured electrolyte mixture. FIG.30 shows a magnetically reactive OLED microcapsule 10 for forming acapacitor OLED microcapsule 10 with the magnetic aligning field turnedon with cured electrolyte mixture. In accordance with this compositionof the OLED microcapsule, the internal phase comprises OLED material anda magnetically reactive material disposed within a first shell. Anelectrolyte and a curable fluid material surround the first shell. Asecond shell encapsulates the first shell, the electrolyte and thecurable material. In response to an applied magnetic field, the positionof the first shell is changeable relative to the second shell. Uponcuring the curable material, the position of the first shell relative tothe second shell is locked in place. This microcapsule 10 structure canbe used to form capacitors/OLED microcapsules 10 which may beparticularly effective for use in passive matrix displays. Typically, apassive matrix display is driven with a relatively high driving energyso that the emission of light by a driven pixel is intense. Thisintensity overcomes the short driving time of the pixel (as comparedwith the more controllable active matrix backplane). This passive matrixdriving scheme results in shorter display life, higher power consumptionand lower display quality. When a charging voltage is applied (such asduring a charging scan of a passive matrix OLED display grid), thecapacitor elements of the microcapsule 10 store applied electricalenergy. The charging voltage can be controllably applied to selectedpixels and in multiple scans to vary the stored charge in themicrocapsules 10 associated with each pixel. When a trigger voltage isapplied (during the display writing scan), the OLED material emits lightin response to the trigger voltage and in a manner dependent on thestored charge. With the proper selection of microcapsule 10 materials,an RC circuit is formed giving the OLED pixel an increased and morecontrolled light emission time and intensity.

FIG. 31 shows a pixel comprised of a chain of capacitor OLED beingcharged by a charging voltage. FIG. 32 shows a pixel comprised of achain of capacitor OLED being triggered for light emission by a triggervoltage. The microcapsules 10 act as capacitor elements that are chargedup with a charging voltage. A trigger voltage is then applied when theOLED pixel is to emit light.

FIG. 33 shows OLED microcapsules 10 randomly dispersed within a fluidbut hardenable carrier fluid 12. A first electrode 14 and a secondelectrode 14 are provided defining a gap there between. Within the gap,field reactive OLED particulate is randomly dispersed within a fluidcarrier 12. The electrodes 14 can be preformed on a substrate, such asglass. Alternatively, one or both grids of electrodes 14 can bepreformed on a flexible carrier 12 enabling roll-to-roll manufacturing.

FIG. 34 shows OLED microcapsule chains aligned within an appliedaligning field formed within unhardened carrier fluid 12. Uponapplication of an aligning field, the OLED field-reactive materialorient along the field lines and form chains within the still-fluidcarrier 12 (analogous to electro rheological fluid mechanics).

FIG. 35 shows OLED microcapsule chains aligned within an appliedaligning field held in alignment within hardened carrier 12. With thealigning field still applied, the carrier 12 is cured (for example,using light or heat) to form a solid phase to lock the chains of OLEDfield-reactive material into position. With the proper selection ofcarrier 12 material, the OLEDs can be energized to create the curinglight to simplify the fabrication process. Alternatively, a light source28 such as a laser or other light emitter, can be used to controllablyapply the curing light.

FIG. 36 shows the OLED microcapsule 10 structure shown in FIG. 35 with adrive voltage applied and light being emitted from the OLED microcapsulechains. When a voltage is applied to the electrodes 14, the OLED chainenables hole and electron movement, raising the energy state of the OLEDmaterial and generating light.

FIG. 37 illustrates a method for forming an OLED particulate having ahole transport layer and an electron transport layer. Hole transportmaterial and electron transport material are combined to form stableparticles. FIG. 37 illustrates the formation of an OLED particle. Holetransport material having a net positive charge and electron transportmaterial having a net negative charge are mixed together in a liquid sothat the opposing polarities of the particles creates an attractiveforce resulting in electrically stable particles. The OLED particulateis formed by providing a first particle, comprised of a hole transportmaterial that has a net positive electrical charge. A second particle isprovided comprised of an electron transport material having a netnegative electrical charge. The hole transport particle and the electrontransport particle are brought together in a liquid and combined to forma unified OLED particulate having a hole transport layer and an electrontransport layer forming a heterojunction between them.

FIG. 38 illustrates a method for forming an encapsulated OLEDparticulate. The hole transport material and the electron transportmaterial can be combined into a single particle by ejecting theconstituent particles towards each other. The positive and negativecharges will attract to form an electrically neutral dielectricparticle. This particle may be coated with an encapsulating shell orleft uncoated.

FIGS. 39-41 show the steps for forming a multi-layered OLED particle. Inthis case, as shown in FIG. 39, individual particles of electrontransport material are imparted with a net negative electrical charge bya charge source 34 and ejected from a nozzle 36. Particles of a blockingmaterial are imparted with a net positive charge and ejected from asecond nozzle 36 towards the stream of electron transport materialparticles. Field applying electrodes 38 may be provided for directingthe respective charged particles so that they combine together to forman electrically neutral dual layer particle. The field applyingelectrodes 38 may also be useful for attracting and removing from thecombined particle stream the charged particles that do not combine inthe dual layer particle. In a similar manner, a dual layer holetransport and photo active layer particles can be ejected with inducedcharges and directed to combine into a dual layer particle containingthe hole transport material and the photo active material. As shown inFIG. 41, the two dual layer particles are imparted with oppositeelectrical charge and ejected from nozzle 36 towards each other wherethey combine to form the completed multi layered OLED particulate. Theamount of charged induced in the particles can be controlled to adjustthe alignment of attracted constituents.

The OLED particulate comprises organic-layered particles, which includea hole transport layer and an electron emitter layer. A heterojunctionis formed at the interface between the hole transport layer and theelectron emitter layer. Each organic-layered particle may also include ablocking layer adjacent to the electron emitter layer and an emissivelayer adjacent to the hole transport layer, thereby forming a stackedorganic layered structure. The blocking layer is provided forfacilitating the flow of electrons from the electron emitter layer, andthe emissive layer is provided for facilitating the emission of photonswhen the energy state of the OLED particulate is raised.

FIG. 40 illustrates a second step in forming a multi-layered OLEDparticulate. The amount of charge induced in particles can be controlledto adjust alignment of attracted constituents. FIG. 41 illustrates athird step in forming a multi-layered OLED particulate. Relatively weakattractive field keeps layered particles properly aligned, withoutcausing attachment of particles to electrodes 14. The relatively morenegatively attractive ETL side attracted to a positive attractive force.More positive towards one end, with an overall net positive charge onHTL/EML layered particle and more negative towards another end, with anoverall net negative charge on ETL/BL layered particle. With the properselection of constituent materials, the electrical properties of the HTLand ETL material should be effective to cause the larger degree ofinduced charge to occur at the those ends of the layered particles.

The OLED particulate may comprise a dielectric OLED microcapsule. TheOLED particulate is formed by the steps of first providing a firstparticle comprised of a hole transport material. The hole transportmaterial has a net first electrical charge. A second particle comprisedof an electron transport material is provided having a net secondelectrical charge. The first electrical charge is of opposite polarityfrom the second electrical charge. The first particle and the secondparticle are brought together to form a unified OLED particulate havinga hole transport layer and an electron transport layer forming ahetero-junction between them. The first particle may further include aphoton-active layer. This photon-active layer may be a light emissivelayer in which case the OLED forms a light emitting device, or a lightreceptive layer, in which case the OLED forms a light-detecting device.

FIG. 42 schematically shows a full-color OLED display, constructed inaccordance with the present invention, having a dichromatic displaylayer for improving the display contrast, power efficiency and forproviding display viewing in bright sunlight. The dichromatic displaylayer may be formed, for example, using a conventional LCD pixilatedlight modulator layer. Further, the dichromatic display layer can becomprised of dichromatic microcapsules that can be oriented to reflector absorb impinging light using an aligning field. The dichromaticmicrocapsules 40 can be oriented using an applied electrical field. Inthis case, the dichromatic microcapsules 40 are electrically reactive.Alternatively, in accordance with the present invention, the dichromaticmicrocapsules may be magnetically reactive. In this case, themicrocapsule can be constructed having a north magnetic pole and a southmagnetic pole, each pole being associated with a respective color of abi-color microcapsule. A construction similar to the capacitor/OLEDmicrocapsule shown in FIGS. 28-32 can be used to create microcapsulesthat can be controllably oriented in an applied magnetic field. Thedichromatic display layer provides a light reflective display for use inbright sunlight and other appropriate ambient light conditions, as wellas other display enhancing effects. The dichromatic pixel layer can beformed adjacent to the last subsequent OLED pixel layer. Thisdichromatic pixel layer results in a display that can viewed in directbright sunlight as well as with improved contrast in indoor ambientlighting conditions. Further, additional subsequent OLED pixel layerscan be provided which emit light in additional color range having acolor and/or light intensity different from the color and/or lightintensity of the other OLED pixel layers.

To control the reflection of the emitted light from the OLED RGB pixelsin automatic mode the OLED brightness and the reflection/absorptiondichromatic microcapsule 40 is automatically controlled to optimizepower consumption and display quality. Photodetection elements are usedto determine that level of ambient light and adjust thereflection/absorption/image displaying capabilities of the inventivedisplay. Further, the inventive OLED device can be configured so as todetect light impinging on a pixel grid formed in accordance with thepresent invention. In this case, the OLED particulate of a first OLEDpixel layer emits electrical energy in response to the reception ofphotons and applies the electrical energy as a detectable signal to thefirst and second layer electrodes 14. Further, a black and white and/orfull color CCD-type camera can be formed, by tuning the wavelength rangeat which subsequent layers of OLED pixels are photo reactive.Photodetectors are used to determine when to use dichromatic displayelements. If the dichromatic pixels (e.g., dichromatic microcapsules 40)are turned to the reflection side, OLED emission will be reflected andmore light emitted from the display. If turned to the absorption side,better display contrast may be obtained. If the OLED layers are turnedoff, the dichromatic pixels become a reflective (or two color) displayfor use in bright light or energy saving conditions. This driving schemerequires very low power-only have to apply power to the pixels to changeorientation, then the state remains until power is applied again. Forapplications such as cell phones, the ability to see a display in brightlight is an important consideration. When the phone is in brightsunlight, the dichromatic display elements are used and the OLEDs areoff and transparent (the display is reflective and monochrome (e.g., ablack and white display)). When the phone is indoors or in lower ambientlight, the emissive pixels are used (full color display). As examples ofhow the dichromatic display layer improves the inventive display, undernormal ambient light (indoor, office lighting) the dichromaticmicrocapsules 40 can be oriented to absorb the reflection of ambientlight to improve the contrast of the display.

In low ambient light (airplane, car, dusk) the dichromatic displayelements can be turned oriented to reflect the OLED emission so that theOLED display elements can be driven with lower energy consumption. Thedichromatic display elements can be automatically oriented andcontrolled to provide power savings and improve contrast. Light filtersand side/side pixels can be mixed with the display stack to create avariety of display options. Further, IR and other emitters and detectorscan also be included to create “invisible” maps that can only be readwith night vision aides. Other display possibilities include windshieldsthat automatically block out high light sources like the sun andoncoming high beams; and goggles that enhance vision, provide nightvision, and include telescopic and stereoscopic capabilities.

FIG. 43 schematically shows the full-color OLED display shown in FIG.42, with the dichromatic pixels oriented for reflecting emitted OLEDlight. When the dichromatic picture elements are reflective (oriented sothat the reflective side of the sphere is facing toward the emissiveside of the display), then the light emitted from the OLED elements isreflected for use in forming the display image. The orientation of thedichromatic picture elements can be automatically controlled dependingon the ambient light detected by a photodetector.

FIG. 44 schematically shows the full-color OLED display shown in FIG.42, showing the relative strength of reflected light depending on thedichromatic pixel orientations. The orientation of each respective pixelstack's dichromatic pixel element, determines the contrast, ambient andemitted light reflectivity.

FIG. 45 shows magnetically-active OLED microcapsules 10 randomlydispersed within a fluid but hardenable carrier fluid 12 along withdesiccant particulate. The carrier fluid 12 can include a conductiveelement, carbon or powdered iron for example. The carrier fluid 12should be selected to have the appropriate electrical properties so thatthe path of least electrical resistance in the completed display deviceis through the OLED material, and not through the carrier 12.Accordingly, the carrier fluid 12 may have a semi-conductivecomposition. Desiccant particles 42 are included within the carrierfluid 12 to improve protection against contamination. The desiccant canbe for example, a finely powdered silica based particulate. Thisdesiccant can be included in the shell and/or the internal phase of theOLAM microcapsules, depending on the microcapsule composition.

FIG. 46 shows the magnetically-active OLED microcapsule chains alignedwithin an applied magnetic aligning field within the unhardened carrierfluid 12. The applied magnetic field can be obtained by permanentmagnets brought into position relative to the display electrodes, orelectromagnets that are controlled to apply the magnetic field as neededto cause the desired microcapsule alignment and orientation.

FIG. 47 shows the magnetically-active OLED microcapsule chains alignedwithin the applied magnetic aligning field held in position within thehardened carrier 12. The carrier fluid 12 can include a conductiveelement-carbon, for example. Desiccant particles 42 are included withinthe carrier fluid 12 to improve protection against contamination.

FIG. 48 shows the magnetically-active OLED microcapsule 10 structurewith light being emitted from the OLED microcapsule chains in responseto a driving applied to the electrodes.

FIG. 49 schematically illustrates a full color OLED display having highintensity visible light display layers and an infrared display layer.

FIG. 50 shows an OLED display layer and a liquid crystal lightmodulating layer 44. The liquid crystal display layer 44 can be used asthe dichromatic display layer described above. The liquid crystal lightmodulating layer 44 can also provide the inventive display with thecapability of being selectively reflective. With this capability, thelight-blocking windshield described with regard to FIGS. 57 and 58 isobtained. Further, a window can be formed that is transparent whenneeded, can be switched to being an emissive display (viewable from bothor only one side), is selectively light blocking, and can be a bi-coloror reflective display.

FIG. 51 shows an inventive OLED display fabricated with thin films oforganic material with photodetection elements. Photodetector elementscan be incorporated into each pixel stack, or disposed in a differentresolution grid. The ambient light, whether sunlight or firelight,received by the photodetectors is used to control the opticalcharacteristics of the OLED pixels associated with each photodetector.This construction can be used with microcapsule-based fabrication or anyother display constructions. This enables features such as windshieldsthat block out (using, for example, LCD shutters) high light sources,such as bright sunshine, overhead streetlights, or headlights beamingfrom another car. OLED solar cell components or pixel layers can be usedto “recycle” the energy emitted by the OLED emitters. Some of theemitted light energy impinges on the solar cells and generate light.This, along with the inventions described herein and the sheet batterydescribed in the above-referenced co-owned Patent Applicant entitled“Printer and Method for Manufacturing Electronic Circuits and Displays”,can enable lightweight, relatively inexpensive, dichromatic newspapers(as described herein in FIG. 1) that recharge in sunlight (or evenindoor ambient light) to enable full-color emissive video or stillimages.

FIG. 52 shows an OLED microcapsule 10 wherein the shell is slightly lessconductive than the encapsulated OLED material. The shell is slightlymore resistive than the OLED material so that current does not flowaround shell, but instead flows through OLED material. The particulatecan be organic or inorganic, with chips of LED material combined andoriented, as necessary, with other materials as is described herein withregard to OLAM materials.

FIG. 53 shows an OLED microcapsule 10 wherein the OLED material isencapsulated along with an electrolyte. A hole transport materialcomprises the shell, and a shell around MAG is insulative to keep themagnetic material from having unwanted influence of the electricalbehavior of microcapsule. OLED material is contained within theelectrolyte solution, the electron carriers in the electrolyte can becontrolled depending on the needed specification of the microcapsules10. For example, the microcapsules 10 charge-carrying requirements ofthe electrolyte can be tailored to match the electrical flow for aparticular OLED constituent material. Thus, microcapsules 10 can beformulated based on the empirically or otherwise determinedcharacteristics of a particular formula, or even a particular batch, ofOLAM. Other additional material can be included in the internal phase orthe shell of the microcapsule, or added to the carrier material, orincluded as other microcapsules 10 within the carrier 12. For example, aphosphorescent OLED microcapsule 10 may require different light-inducingapplied electrical energy. Light of a particular wavelength, for exampleinfrared, can trigger the OLED emission at other wavelengths. In thiscase, OLAM, or other material such an inorganic semiconductor, isincluded to generate electricity in response to IR light. The generatedelectricity is used to cause an emission of other wavelengths of lightby the OLED pixel layers. This capability makes possible a map, forexample, that can be read with an infrared flashlight (keeping thestealth advantage, while avoiding the need for the map reader to havenight vision, as is the case when the map is the IR emitter).

FIG. 54 shows an OLED microcapsule 10 wherein the OLED material and thehole transport material are contained in solution within a conductiveshell. This construction may be driven with AC or DC current. The OLEDparticulate is formed, by microencapsulating an internal phase within ashell. The internal phase or the shell includes an OLED material andeither the internal phase or the shell includes a field reactivematerial. The field reactive material comprises either or both anelectrostatic and a magnetically reactive material. In accordance withanother composition of the inventive microcapsule, the internal phasecomprises an OLED emitter material and an OLED hole transport materialdispersed in solution. Color dyes may also be included within theinternal phase. The solvent may be a fluid organic solvent. In order toprovide the alignment capabilities of the microcapsules 10, either theinternal phase or the shell may include a field reactive component.

FIG. 55 shows the OLED microcapsules 10 shown in FIG. 54 including amagnetically active material. The magnetic material is included as aseparate microcapsule 10 with an electrically insulative shell containedwithin the internal phase of a second conductive shell that alsoencapsulates a solution of the OLED material (electron transportmaterial and hole transport material). The electrically insulatedmagnetic material enables microcapsule 10 alignment within a magneticfield, without it becoming an electrical short within the microcapsule.The OLED microcapsules 10 can have constituent parts including at leastone of hole transport material, electron transport material, fieldreactive material, solvent material, color material, shell formingmaterial, barrier material, desiccant material, colorant material, lightcurable, heat expandable, heat contracting, heat curable and heatmeltable material. The constituent parts of the microcapsule 10 form atleast one internal phase and at least one shell. The constituent partsare selected so as to have electrical characteristics that result in apreferred path of electrical conduction (or electron and hole mobility)through the hole transport material and the electron transport material.By this construction, the microcapsule 10 behaves as a pn junction uponapplication of an electrical potential to the first electrode 14 and thesecond electrode 14.

FIG. 56 illustrates the OLED microcapsule 10 shown in FIG. 54 used forcreating a general lighting or display back lighting OLED device. Forgeneral lighting purposes, OLED and hole transport material ismicroencapsulated in solvent form. The microcapsules 10 are randomlydispersed within a conductive carrier 12 material, for example aconductive epoxy mixture. The microcapsules 10 can be disposed betweentwo planer electrodes 14. The “self-healing” capabilities describedherein are used to correct electrical shorts between the planarelectrodes 14.

FIG. 57 illustrates a transparent, flexible OLED display fabricated foruse as part of a vehicle windshield. A liquid crystal (or other)light-modulating grid may also be included. The light-modulating grid isused to provide a shutter for blocking high intensity light source 28,such as the sun and oncoming headlights. Photodetector elements (whichmay be included in grid form within the windshield and/or in anotherarrangement such as an array) detects when a light source 28 is at ahigher intensity than the ambient light. At the location of the detectedhigh intensity light source 28, the light is shuttered (e.g., liquidcrystal within certain pixels is oriented) so that the incoming light isblocked. A radar system, IR camera of other object detecting system canbe used to determine when an object is in the road, such as a deer or adog. If such an object is detected, its image of that object or someindication is produced in the OLED display at the location on thewindshield corresponding to where the object would be viewed by thedriver. Information, such as speed, radio channel, incoming cell callnumber, etc., can be displayed by the OLED display as a heads up displayimage. For an example of a driver circuit for the light shutter, aphotoactive grid generates an electrical potential between twoelectrodes 14. That electrical potential (amplified if necessary) iseffective to cause structures (molecules or crystals or molecularchains) to orient so that light is selectively blocked. This mechanismmay also be used to create a fresnel-type lens system (creating acurvature (focus ability) of a received light image using an essentiallyflat optical element.

FIG. 58 is a block diagram showing the basic components of a driverdisplay system using an OLED display. A controller controls a displaygrid and receives input from a photodetector grid. A display driverdrives the display grid, under the control of the controller, inresponse to the photodetector grid, an IR camera and/or other detectionsystem such as a radar, sonar, ultrasonic, or the like.

FIG. 59 illustrates an OLED light emissive element. The OLED element canbe constructed from sheets of OLED organic material stacks 46, and canbe formed on glass or plastic substrates 24 and cut to size. Theelectrode 14 leads can be fixed to the cut OLED stack 46 and disposedwithin an evacuated or inert gas filled bulb. The bulb can be solid andtransparent or light diffusive, forming a robust, solid state, lightbulb for flashlights or other applications where a conventional LED mayotherwise be employed.

FIG. 60 shows the OLED light emissive element having a conventionallight bulb form factor. OLED light can be fabricated into the same formfactor as a conventional light bulb so that it can be easily installedinto existing light sockets. The orientation of the organic stack 46,reflective anode and transparent anode enables the light to be projectedoutward from the bulb. An array of devices can be configured so that thelight is emitted in an omni-directional or directional manner. The OLEDelement can be constructed from sheets of OLED light stacks 46, and canbe formed on glass or plastic substrates 24 and cut to size. Theelectrode 14 leads can be fixed to the cut light stack and disposedwithin an evacuated or inert gas filled bulb. The threaded portion ofthe bulb can include an ac to dc converting circuit so that theconventional sockets, lampshades, etc., already in the home or officeare still usable. Alternatively, another form factor, such as holidaylighting, rope lighting, etc., can be used. The cut OLED light stack canbe shaped as desired, square, long and thin, etc. Also, the same basicstructure can be used to make OLED light in a conventional LED package.

FIG. 61 illustrates an OLED device fabricated using light emissivelayers and light detecting layers. The OLED display device can includelayers of light emission pixels and layers of light detection pixels.The light detection pixels can be used to detect ambient light andcontrol the intensity of the light emission pixels. As with some of theother device constructions described herein, the formation of the OLEDpixel layers can be done using the inventive microcapsule 10 fabricationmethod and/or a combination with other fabrication methods such asinkjet, spin coating, vacuum deposition, evaporation, etc. for formingan OLED organic stack 46.

FIG. 62 illustrates stereoscopic goggles having OLED display deviceelements 48. The photodetection pixels can be formed so as to effect acamera incorporated within the OLED display device elements 48. Thecamera optics can include lenses that change shape and/or focal pointdepending on whether the image is focusing on the human eye or thecamera pixel elements. Alternatively, or in addition, CCD-type cameras50 can be provided adjacent to the OLED display device elements 48.

FIG. 63 illustrates a flexible OLED display having a curvature thatcompensates for the human eye's range of motion. The image displayed onthe curved wraparound OLED display is refreshed so that the eye movementas well as the head movement of the user is accounted for. With thisstereoscopic vision aide, the user's head movement can be determined byaccelerometers and gyroscopic circuits. The eye movement is determinedby reflecting IR (or some wavelength depending on the ambient light) offthe retina and detecting the reflection by photodetectors which may beincorporated in the OLED display

FIG. 64 illustrates a flexible OLED display having microlens elements 52for focusing emitted light at the appropriate physical location within ahuman eye. An optical lens can be used to focus light onto CCD-typeelements to create microlens elements 52 that focus the pixel lightsource 54 at the focus spot in the human eye. The optical properties ofthe microlens element 52 can compensate for vision problems

FIG. 65 illustrates a wraparound visor 56 having a curved, flexible OLEDdisplay and speakers 58. The inventive stereoscopic vision aid has ahigh resolution OLED display. The OLED display is shaped so that fieldof vision is as full as practical.

FIG. 66 illustrates a wall 60 of a house having an inventive OLEDdisplay window 62, the window 62 being driven so as to be transparentwith trees 64 outside the house visible through the window 62. Theinventive window 62 can be constructed along the lines of the OLEDdisplays described herein. As will all of the applications for theinventive OLED technology, the various elements comprising the variousversions of the invention described herein can be mixed and matcheddepending on the intended use for a particular OLED display. Thus, inthis case, the inventive window 62 can be driven so that is transparentwhen needed, can be switched to being an emissive display (viewable fromboth or only one side), is selectively light blocking, and can be a fullcolor, multi-color, monochrome or reflective display.

FIG. 67 illustrates the wall 60 of a house having the inventive OLEDdisplay window 62, the window 62 being driven so as to display multiplesimultaneous video streams 66 including videophone communication,Internet web page and a television program. Multiple streams of displayinformation 66 can be simultaneously received and displayed. Forexample, broadcast video content such as a television program may beshown at a first portion of the display, personalized video content,such as a videophone conversation may be shown at a second portion and aweb page, including mapped hyperlink content, may be shown at a thirdportion. With an LCD light modulating layer, the content displayed onthe inventive OLED display window 62 can be viewable from outside thehouse (from poolside, for example), or LCD light modulating layer can becontrolled so that the emitted display light can be blocked from viewfrom outside the house.

FIG. 68 illustrates the wall 60 of a house having the inventive OLEDdisplay window 62, the window being driven so as to be a mirror. In thiscase, the LCD light modulating layer can be controlled to block lightfrom being transmitted through the window. Further, as shown in FIG. 57,relatively high intensity light (such as from sun beaming onto thewindow) can be selectively blocked to prevent glare within the house andto keep the house cooler in the summer.

With respect to the above description, it is realized that the optimumdimensional relationships for parts of the invention, includingvariations in size, materials, shape, form, function, and manner ofoperation, assembly and use, are deemed readily apparent and obvious toone skilled in the art. All equivalent relationships to thoseillustrated in the drawings and described in the specification areintended to be encompassed by the present invention.

Therefore, the foregoing is considered as illustrative only of theprinciples of the invention. Further, since numerous modifications andchanges will readily occur to those skilled in the art, it is notdesired to limit the invention to the exact construction and operationshown and described. Accordingly, all suitable modifications andequivalents may be resorted to, falling within the scope of theinvention.

1) A method for forming an organic light active device, comprising thesteps of: providing a first electrode and a second electrode defining agap there between; disposing within the gap organic light activeparticulate dispersed within a carrier. 2) A method for forming anorganic light active device according to claim 1; wherein the organiclight active particulate comprises field reactive organic light activeparticulate randomly dispersed within a fluid carrier; and furthercomprising the step of applying an aligning field between the firstelectrode and the second electrode to form a desired orientation of thefield reactive organic light active particulate within the fluid carrierbetween the first electrode and the second electrode. 3) A method forforming an organic light active device according to claim 2; wherein thecarrier comprises a hardenable material; and further comprising thesteps of hardening the carrier to form a hardened carrier formaintaining the desired orientation of the organic light activeparticulate within the hardened carrier. 4) A method for forming anorganic light active device according to claim 1; wherein the organiclight active particulate is formed by the steps of providing a firstparticle comprised of a hole transport material having a net firstelectrical charge and providing a second particle comprised of anelectron transport material having a net second electrical charge, thefirst electrical charge being opposite polarity from the secondelectrical charge; bringing the first particle and the second particletogether to form a unified organic light active particulate having ahole transport layer and an electron transport layer forming aheterojunction between them. 5) A method for forming an organic lightactive device according to claim 4; wherein the first particle furtherincludes at least one of an emissive or receptive photon-active layer.6) A method for forming an organic light active device according toclaim 1; wherein the organic light active particulate is formed bymicroencapsulating an internal phase within a shell, at least one of theinternal phase and the shell including an organic light active materialand at least one of the internal phase and the shell including a fieldreactive material comprising at least one of an electrostatic materialand a magnetically reactive material. 7) A method for forming an organiclight active device according to claim 1; wherein the organic lightactive particulate is formed by microencapsulating an internal phasewithin a shell, the internal phase comprising at least one of an organiclight active emitter material and an organic light active hole transportmaterial in a solution. 8) A method for forming an organic light activedevice according to claim 7; wherein at least one of the internal phaseand the shell includes a field reactive component. 9) A method forforming an organic light active device according to claim 1; wherein atleast one of the first electrode and the second electrode comprises anelectrode grid for forming organic light active pixels between the firstelectrode and the second electrode. 10) A method for forming an organiclight active device according to claim 1; wherein the organic lightactive particulate dispersed within the carrier is disposed within thegap through a nozzle. 11) A method for forming a light active deviceaccording to claim 1; wherein the organic light active particulatedispersed within the carrier is disposed within the gap through aninkjet nozzle. 12) A method for forming an organic light active device,comprising the steps of providing a fluid carrier; dispersing organiclight active particulate within the fluid carrier; providing a firstelectrode layer; coating a layer of the fluid carrier dispersed with theorganic light active particulate on the first electrode layer; andproviding a second electrode layer on top of the coated layer of thefluid carrier dispersed with the organic light active particulate. 13) Amethod for forming an organic light active device according to claim 12;wherein the organic light active particulate comprises field reactiveorganic light active particulate randomly dispersed within the fluidcarrier; and further comprising the step of applying an aligning fieldbetween the first electrode and the second electrode to form a desiredalignment of the field reactive organic light active particulate withinthe fluid carrier between the first electrode and the second electrode.14) A method for forming an organic light active device according toclaim 13; wherein the carrier comprises a hardenable material; andfurther comprising the steps of hardening the carrier to form a hardenedcarrier for maintaining the desired alignment of the organic lightactive particulate within the hardened carrier. 15) A method for formingan organic light active device according to claim 12; wherein the firstelectrode layer comprises an x-electrode layer having x-electrode lines;the second electrode layer comprises a y-electrode layer havingy-electrode line disposed adjacent to the x electrode layer and defininga gap therebetween so that pixel volumes are defined at intersections ofrespective x-electrode lines and y-electrode lines. 16) A method forforming an organic light active device according to claim 12; whereinthe organic light active particulate is effective receiving through thecarrier electrical charges from the first electrode layer and the secondelectrode layer and generating photon emissions in response to receivingsaid electrical charges. 17) A method for forming an organic lightactive device according to claim 12; wherein the organic light activeparticulate is effective for receiving a photon and separatingelectrical charges in response to the received photon, the separatedelectrical charges being transfer through the carrier to the firstelectrode layer and the second electrode. 18) A method for forming anorganic light active device according to claim 12; wherein the organiclight active particulate dispersed within the carrier is coated on thefirst electrode layer through a nozzle. 19) A method for forming a lightactive device according to claim 12; wherein the organic light activeparticulate dispersed within the carrier is coated on the firstelectrode layer through an inkjet nozzle. 20) A method for forming alight active device, comprising the steps of providing a fluid carrier;dispersing light active particulate within the fluid carrier; providinga first electrode layer; coating a layer of the fluid carrier dispersedwith the light active particulate on the first electrode layer; andproviding a second electrode layer on top of the coated layer of thefluid carrier dispersed with the light active particulate. 21) A methodfor forming a light active device according to claim 20; wherein thelight active particulate comprises field reactive light activeparticulate randomly dispersed within the fluid carrier; and furthercomprising the step of applying an aligning field between the firstelectrode and the second electrode to form a desired alignment of thefield reactive light active particulate within the fluid carrier betweenthe first electrode and the second electrode. 22) A method for forming alight active device according to claim 21; wherein the carrier comprisesa hardenable material; and further comprising the steps of hardening thecarrier to form a hardened carrier for maintaining the desired alignmentof the light active particulate within the hardened carrier. 23) Amethod for forming a light active device according to claim 20; whereinthe first electrode layer comprises an x-electrode layer havingx-electrode lines; the second electrode layer comprises a y-electrodelayer having y-electrode line disposed adjacent to the x electrode layerand defining a gap therebetween so that pixel volumes are defined atintersections of respective x-electrode lines and y-electrode lines. 24)A method for forming a light active device according to claim 20;wherein the light active particulate is effective receiving through thecarrier electrical charges from the first electrode layer and the secondelectrode layer and generating photon emissions in response to receivingsaid electrical charges. 25) A method for forming a light active deviceaccording to claim 20; wherein the light active particulate is effectivefor receiving a photon and separating electrical charges in response tothe received photon, the separated electrical charges being transferthrough the carrier to the first electrode layer and the secondelectrode. 26) A method for forming a light active device according toclaim 20; wherein the carrier dispersed with the light activeparticulate is coated on the first electrode layer through a nozzle. 27)A method for forming a light active device according to claim 20;wherein the fluid carrier dispersed with the light active particulate iscarrier is coated on the first electrode layer through an inkjet nozzle.